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IndonesiaDecember 2011

SAND No. 2009-8395PSandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin

Company,for the United States Department of Energy’s National Nuclear Security Administration

under contract DE-AC04-94AL85000.

• Definition of chemical safety

• Hazard vs Risk

Assessment Process – anticipation, recognition, evaluation and controls

• Chemical Management• Chemical Management

Benefits

Procurement

Storage

Inventory Systems

Hazard Communications

Waste Management

Safety: “The condition of being safe from undergoing or causing hurt, injury, or loss” ◦ Merriam-Websterhttp://www.merriam-webster.com/dictionary/safety

Chemical Safety: “Practical certainty that there will be no f f bexposure of organisms to toxic amounts of any substance or

group of substances: This implies attaining an acceptably low risk of exposure to potentially toxic substances.”◦ IUPAC Glossary of Terms Used in Toxicologyhttp://sis.nlm.nih.gov/enviro/iupacglossary/glossaryc.html

Also:◦ Process Safety◦ Inherent Safety

Hazard – the inherent potential to harm

Risk – the probability that harm will result

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Chemical hazards◦ Health hazards: toxics, corrosives, carcinogens◦ Physical hazards: flammables, explosives, reactives

Other industrial hazards◦ Mechanical-unguarded moving parts, belts, fans◦ Electrical◦ Pressure & temperature extremes◦ Elevated surfaces◦ Noise◦ Non-ionizing radiation-lasers, ultraviolet light,

radiofrequency◦ Ergonomic hazards

Anticipation

Recognition

Risk Assessment Process Risk Assessment Process

Evaluation

Control

Hazards Risks

Anticipation = Advance Planning: Team with process engineers,

plant facility team leaders, workers, environmental, health & safety professionals,

fire protection engineers

Acquire process i f i d iinformation, drawings,

equipment requirements and specifications, chemical information, safety data sheets,

plant safety procedures, and regulatory requirements

Identify each chemical hazard◦ Quantity of each process chemical◦ Identify intermediates, by-products◦ Acquire toxicity information◦ Solid, liquid, or gas?◦ Flashpoint◦ Flashpoint◦ Vapor pressure◦ Air or water reactivity

Identify process hazards◦ Upper and lower limits of temperature, pressure, flow◦ Mechanical hazards◦ Electrical hazards

http://www.ilo.org/safework/info/databases/lang--en/WCMS_145760/index.htm

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What are the tasks in the process? How are chemicals used?--Filling, spraying, reacting, mixing?

What are the controls for over-pressurization or elevated temperature conditions?

Process equipment inspected & maintained? Process equipment inspected & maintained? Barriers and guards in place? Workers properly trained? What are the consequences of process

deviations? Emergency shut-down equipment or

ventilation?

How are the risks controlled?

• Eliminate the hazard

• Substitute process materialsSubstitute process materials

• Engineering controls

• Administrative controls/operational practices

• Personal Protective Equipment (PPE)

ControlsControls

Change the processeliminate the hazard

(e.g. Lower process temperature)

Substitutionless-hazardous substance

(e.g. - cyclohexane for benzene)

Engineering ControlsEngineering Controls

Enclose the hazard,Use a barrier,

Or,

Ventilate-Dilution ventilation

-Local exhaust ventilation (LEV)

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Organizational safety policies, Standard operating procedures, p g p ,

Task-specific procedures

PPE is the least desired controlDoes not eliminate the hazard

Depends on worker complianceMay create heat stress

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Benefits Cradle to Grave Model Procurement Storage Use Disposal

•Reduces cost of:•Raw materials•Hazardous waste disposal

•Facilitates plant sustainability

Chemical Management BenefitsChemical Management Benefits

WasteNew Chemical

p y

•Protects the environment

•Improves security•Theft•Sabotage

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Procure Store

U Di lUse Disposal

Institute a procurement approval systemo Written procedure Document who orders chemicals Document what chemicals require approval

Wh Who approves o Link ordering to a product review system Engineering, Environmental Health &

Safety, Facility & Fire Protection Staffo Track “chemicals of concern”

How are chemicals procured at your facility?o What are there rules about who can order chemicals?

How do you track the purchase of – How do you track the purchase of –o highly toxic, o flammable, or o reactive chemicals?

Where are chemicals stored?

Consider unusual storage sites ◦ Loading docks◦ Outside locations◦ Outside locations◦ Waste storage facility◦ Chemicals contained in

equipment Resource

Guidelines for Safe Warehousing of Chemicals, Center for Chemical Process Safety, ISBN: 978-0-8169-0659-8

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Design and Construction:◦ Building and fire codes are specific for each country◦ U.S. uses International Code Council

http://www.iccsafe.org/◦ Combines many building, fire, and energy codesCombines many building, fire, and energy codes ◦ Incorporates by reference

National Fire Protection Association (NFPA) Codes

NFPA Electric Code (70)

Best Practices: Safe path during normal and

emergency conditions Determine travel distance

ito exits Separate personnel areas

from chemical storage Adequate aisle spacing Exit signage Emergency lighting

Design and Construction: Spill containment◦ Maximum probable spill

plus fire sprinkler water◦ Primary containment

Drains, trenches◦ Secondary containment

Recessed loading dock

Concrete berms, grates

Separate incompatible chemicals◦ Oxidizers, corrosives, flammables

Chemical StorageChemical Storage

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Gas Cylinders: Separate incompatible

gases Secure all gas cylinders Store in well-ventilated

area Provide protection from

direct sunlight Screw down cylinder caps

when not in use

Chemical StorageChemical Storage

Danger of Propylene Cylinders in hot weather -Video file = Praxair Clip (small).mpg 8.5 min

Tank Storage: Tank material compatible with

the chemical stored◦ Mild Steel◦ Stainless steel◦ Cross-linked high densityCross linked high density

polyethylene

Spill containment◦ Double walled or lined

tanks◦ Berms

Security/Impact protection

Photo credit: Bailiff Enterprises, Inc. Houston, Texas

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What safeguards does your facility have in place to prevent, mitigate, or respond to a

release in a chemical storage area?

• Home made – Access or Excel programs

• Commercial – Chemical inventory linked to Safety Data Sheets (SDS)Data Sheets (SDS)

• Freeware – Web-based, Hypertext Preprocessor (PHP) software

• Radiofrequency Identification (RFID) tracking

• System of tracking is container-based or static inventory

• Each container, tank, or cylinder is provided with a barcode stickerbarcode sticker

• Barcode labels may be printed using a direct thermal printer

Photo credit: Fabian M. Dayrit and Jaclyn Elizabeth R. Santos

Chemistry DepartmentAteneo de Manila UniversityLoyola Heights, Quezon City

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Advantages:• Query for container location• Link a chemical container to safety data

sheet• Track chemicals of concernTrack chemicals of concern• Document disposal or waste transfer

Recommendations:• Perform a periodic site inspection

-Assures accuracy of the inventory-Provides visual inspection of container

conditionPhoto credit: Fabian M. Dayrit and

Jaclyn Elizabeth R. Santos

System should be able to query for the following: ◦ Barcode number◦ Trade or IUPAC name◦ Chemicals in a mixture◦ CAS number◦ Location (process unit)◦ Quantity◦ Shelf life/expiration date Lab chemicals

Barcode Location Depart. Quantity Purchase Date

Expiration Date Name State Waste

Disposal

XX00187 110/1111 02712 40 liters 8/01/200

7BKC 20121 Liquid

XX00172 110/1111

02712 80 liters 7/31/2007

DIETHANOLAMINE

Liquid

dXX00173 110/1111 02712 20 liters 11/18/20

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ACETONE Liquid x

XX00174 110/1111

02712 28 liters 12/15/2010

ACETONE Liquid

XX00175 110/1111

02712 40 liters 10/17/2010

ISOAMYL ACETATE

Liquid

XX00176 110/1111

02712 20 liters 11/18/2010

SOLVENT 25

Liquid

Commercial systems typically include:◦ Barcode Scanner◦ Database◦ Link to safety data sheets

May also include: May also include: ◦ Link to chemical suppliers◦ Report function

Reportable chemicals Community Right-to-Know, air emissions, etc.

Internal reports

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Globally Harmonized System (GHS) Hazard pictograms Signal words Hazard statements

U.S. OSHA Label all chemical containers

Product or chemical name Supplier name/contact information Hazard

A Guide to The Globally Harmonized System of Classification and Labeling of Chemicals: http://www.osha.gov/dsg/hazcom/ghs.html

DangerFlammable Liquid

Pipe Labeling◦ 2007 ANSI/ASME A13.1

Scheme for the Identification of Piping SystemsDoes not apply to◦ Does not apply to buried pipelines or electrical conduit

◦ Label must state contents, hazard, direction of flow

◦ May use color coding

Photo Credit: Seton Identification Products. http://www.seton.com/catalog/product/view/

Safety Data Sheet:1. Identification2. Hazard(s) identification3. Composition information4. First-aid measures5. Fire-fighting measures6. Accidental release measures7. Handling and storage8. Exposure control/personal protection

9. Physical/chemical properties10. Stability and reactivity11. Toxicological information12. Ecological information13. Disposal considerations14. Transport information15. Regulatory information16. Other information

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What chemical labeling system does your facility use?

Is the labeling system the same for all containers?

How do workers and emergency response staff access safety data sheets in the event of an incident?

Substitute chemicals when process permits

Recycle

Dispose by incineration, if allowed in your country

I j ti ll d i U S Injection wells used in U.S.

Incineration is NOT the same as open burning

• Hazard vs Risk

Assessment Process – anticipation, recognition, evaluation and controls

• Chemical Management

Benefits Benefits

Procurement

Storage

Inventory Systems

Hazard Communications

Waste Management